Apparatus for making transmission cables



June 22, 1948.

c. -A. ARENS APPARATUS FOR MAKING TRANSMISSION CABLES 3 Sheets-Sheet 1Filed June 28, 1944 INVENTOR. v 6/207 25'4 flrz/w ,BY;

June 22, 1948. c. A. ARENS 2,444,001

APPARATUS FOR MAKING TRANSMISSION CABLES Filed June 28, 1944 s SheetsSheet 2 -J41 J06 I I i i J05 J J 2 1 26 J5Z ml? J55 J05 15 INVENTOR. I6mrlasd Gyms J36 J56 J06 J35 BY June 22, 1948. c. A. ARENS 2,444,001

APPARATUS FOR MAKING TRANSMISSION CABLES Filed June 28, 1944 ssheets-sheet s .forth for purposes of illustration.

In the drawings, wherein like reference nu- Patented June 22, 1948APPARATUS FOR MAKING TRANSMISSION I CABLES Charles A. Aren s, Chicago,Ill., assignor to Arens Controls, Inc., Chica Illinois go, 11]., acorporation of Application June 28, 1944, Serial No. 542,581

6 Claims.

This invention relates to methods and appa- L ratus for makingtransmission cables of the type adapted to transmit mechanical forcesand movements between predetermined operating stations.

It is an object of the invention to provide new and improved methods andapparatus for makapparatus for making transmission cables of improvedconstruction and i which have improved operating characteristics inservice. 7 w

Further objects of the invention are to provide improved means andmethods for making a composite inner shiftable structure fortransmission cables ofthe type defined, in a continuous singleoperation; and wherein the size and stiffness. of the structure may beaccurately controlled; and wherein the forming of the structure atthe'form ing station is effected inabalanced manner and with a minimumdistortion and stress of the parts.

Various other objects, advantages and features of the invention will beapparent from the following description when taken in connection withthe accompanying drawings wherein certain preferred embodiments of theinventionare set merals refer to like parts throughout: r

Fig. 1 is a general plan View of an apparatus 1 for forming mechanicaltransmission cables, em-

bodying the principles of the invention and adapted to carry out themethods thereof;

Fig. 2 is a side elevation of the apparatus illus- .,tratedin Fig. 1;Fig. 3 is a detail view on an enlarged scaleof the inlet guide rollerfor the core wire, taken as indicated by the line 3-3 of Fig. 2;

Fig. 4 is a detail view on an enlarged scale of the winding or forminghead structure, taken as indicated by the line 4-4 of Fig. 2;

, Fig. 5 is a View of, the winding head structure,

takenfas indicated by the broken line"5 5 of Fig.4; H Fig. 6 is a detailperspective view of one of the z head, and more particularlyillustrating the forming or Working dies;

Fig. 8 is a transverse sectional view of the structure of Fig. 7, on theline 88 thereof;

Figs. 9 and 10 are views similar to Fig. 7, but illustrating modifiedembodiments;

Fig. 11 is a detail sectional view of a part of the structure of Fig.10, and taken as indicated by the line H-! l thereof;

Fig. 12 is an illustrative view showing a modification; 1

Figs, 13 and 14 are views illustrating a modified' reel support for thewindin head, Fig. 13 beingtaken as indicated by the line l3-!3 of Fi 14;

Figs. 15, 16 and 17 are views showing the completed shiftable innercable structures, arranged within their associated housing sheaths;

Fig. '18 is a detail view on a magnified scale 11- lustrating the detailof the cable structure, as made by the machine; and

Fig. 19 is a partial view illustrating a modified feeding arrangementforcontrolling the feeding speed of the cable structure in its passagethrough the machine.

This application is a continuation-in-part of my copending application,Serial No. 538,170, filed May 31, 1944, now Patent No. 2,438,380, March23, 1948, and entitled Transmission cable. The present case relates toapparatusand methods for making the cable structure ofsaid copendingapplication.

Referring to the drawings, and first to the embodiment of the inventionillustrated in Figs. 1 to 8 inclusive, in Figs. 1 and 2 an apparatus isillustrated comprising an integral frame structure lllby means of whichthe various elements of the machine are supported. Carried at one end ofthe frame is a pair of support brackets H' and I2 adapted toreceive thesupport shaft l3 of a supply reel l4 upon which the core wire, I5 whichis to form a part of the completed cable structure, is-wound. The shaft"I3 is freely removable from the support brackets ll and [2 to permitready removal and replacement of the core wire supply reels, so as topermit replacement and the use of different types and kinds of coreWires, as will be required. A spring pressed collar l6 may be employedto impart a light frictional drag to movement of the supply reel.

The core wire I5 is lead from the supply reel l4 over a-guide roller orwheel ll, Figs. 1, 2 and 3, by means of which the wire is guided into arotatable guide sleeve l8, and also by means of which a controlledadjustablefrictional drag may,

3 if desired, be imparted to the Wire. More particularly, referring toFig. 3, a support bracket 19 is carried by the machine frame Hi, thissupport bracket in turn carrying a pair of upstanding support blocks 20and 2| provided with, aligned openings. I A non-rotatable shaft 22 iscarried within these openings, said shaft having an enlarged portion 23at one endfwith'in the opening of the member 20, and the other end of thshaft being threaded for threaded engage--- ment within a sleeve 24provided with-an-adjust able hand wheel 25. The roller I? is rotatab'lymounted upon the shaft 22, and a pairof friction discs at and 21 aredispesee an ei pesi sides of the wheel, as indicated. The enlarged shaftportion 23 may be splined or otherwise non-rotatably secured within itssateen bloekiil; It will be seen that by rotational mechanicaladjustment of the hand whee12'5, the sleeve Mane-enlarged shaftportion23may be brought to bear "against "the friction discs {26 and -Z Iwhereby to impart a frictional drag ponthe 'r'oll'er fiend uponiieeore'wir nee d.

A main driving motor 30, preferabl'y provided with a" vari'ame s eereduction "drive e i ar- -anged to operate a maifnjdrji-ve-'shaft 3 2,This drive s aft car'ii ese pair ei-dnve pul'le'ys es engagedpy thebeltsee, wire jtperive a; pair of driven pul1eys35 secured "an elongateddrivifi'g 's le'e'l le '36 disposed for "T Ut a tion' at the Tipper partof the machine. Thisdriving sleeve is urnalle'd'in a j'pai of jbarings'3-1 asses, and' i's ri idly1c'onnected'ftothe heave 18; the latter beingjour'n a lled for rotation ina teamee. The sleeves l8 and 36 are rigidlyconnected together and ar disposedinj longitudinal continuation, so "thecore "wire i'emaylq passed continuouslythe'rethrough The winding head,generally indi'ca'ted'by' thennfmral'fie" is rigidly =-earfied by theSleeve 36. Thebdhst'fllbtibfi of the head will be later described,

4a and 4a,. e end of the siiittt' carries a b'ev- I 'a h'ait )52,extending longitudinally of the machirie. QIhis shaft 2"isconnected"toadrive shaft 533 thi iiugii "the intermediary *ofa change speed "windinneed; is wrapped aroun the wheel "62 fand'fthenfpjassesto a take-upreel64 'upon which fit is Cdild and stored'for use. twill b ee'l lthat by"controlling the drivenspeed' o'f rotation of 'the wheel 62, throughtheintermediary of thech'a'nge speedgear box 5'43thesfieedoftravlof-thebompleted' cable structure may "-be' aeci'i iateiy cendescribed.

Means ispreferablyprovided foryildably driv- 32 is provided on its endwith a gear 68, Fig. 2,

adapted to mesh with and drivea gear 69 secured to a longitudinallyextending shaft 10 jour palled in a pair of bearing brackets H and 12.The end of the shaft 10 carries a friction disc 13 spring pressed bymeans of a spring 14 into engagement with a co-mating friction disc 15secured to one end of a stub shaft iournalled in ema in block The otherend of this stub "shaft" carries-a bevel gear 18 adaptedto mesh with anddriveabevel gear '19 carried on one end 'of'astub shaft :journalled in abearing block 80.

The other end of this latter stub shaft is adapted "to be 'rem-ovablyconnected by means of a key connection 8| with the axle shaft 82 of thetakeup reel 64, the shaft '82 being removably mounted with-in aqjairdfrsupportbrackets fi andfld.

1 It Willi'be seen'that by reason of theconne'ctions provided, theta'ke-up reel' 64 will be yieldably driven from the shaft 10 duringoperation of the machine. However, while the speed of the shaft 1 0 maybesubst'antially constant, due to the slip drive-connection 13- 15,-only suchproper speed of rotation will be imparted to the take-up reerasis' necessary to keep the cable 63 taut. Dneto" the key connection '81,the -take=up reel tflmay'be readily removed from the frame supportbrackets 83 and '84-, wherebyto permit re- ';placement and substitutionof different take-up reels," as will be understood. When the wheel 152"is being driven from the "change speedwgear box 54, its speed ofoperation determines 'thelongi'tu'dinal speedof travel time cable 63.When the change-speed :gear box is adjusted to dis- -'con-rieot theshafts 52" and-53, so that the-Wheel GT-is arranged for free rotation;the longitudinal speed'tif travel of the cable-is controlled by the'a'otion of the/winding head; as will presently be described.

' The'windi'ng or forming head M -is best illustrated in 'Figsfil, 5, 6,'7and '8. Referring firstto Figs. 4 and 5, it will be seen that thewinding *h'e'ad comprisesapair' of clamp blocksell and 9! 7 arranged tocooperatively Fgri' and thus be se- *cu'redtothe"elongatedidrivingsleeve 36, for irotajtionflthe'rewit-h.'More'particularlm a' pair of'bolts 92 and J3 :extend tliroughtheblo'c'ks 90 =and 9|, projecting therefrom in opposite directions.

These "bolts are provided with threaded- 1 nuts 94 and with shoulders95, whereby as 'the muts are t""1'i'te11"ed upon the bolt's the cla'mpblocks 90 and "fribtiohal dragi In 'order to impart-"such f'rictiorfelldrag, friction di's'cs I110 are provided, re-

spectively engageable'with the 'reels, being urged into frictionalengagement by means of com- "pressien springs m l'," th'e ten'si'onofwhi'ch m'ay be controlled by 'the adjustable lock nuts 1112. By

niefa'n's of the look riuts,- a 'r e determined desired drag-maybeplaced-upon the supply reels; inth'eir rotation upon the bolts.

" The supply reel 98 l is adapted to supply a" wire its the winding orforming station, Whereas the supply reel 99 is adapted similarly 'tosupply a" wir ms. v 'To guide the wire I 1-05 m its inoveiiients, a rsupport: bracket ms mounted on the clamp block III by means of bolts I09is provided for supporting a pair of guide rollers I I and III. Theshaping of the support bracket I08 is illustrated in perspective detailin Fig. 6. The bracket is provided at its end with an opening II2adapted to rotatably receive the shaft portion H3 of a bifurcated oryoke member H4 in which the guide roll H0 is rotatably supported. Thebracket I08 is also provided on its end with a depending portion I I 5provided with an opening II 6 for receiving the axle shaft I I! of theguide roller III. It will be seen that the rollers II 0 and III guidethe wire I05 from the supply reelto the winding station, the yoke memberII4 being swiveled on its support shaft I I3 to accommodate themovements of the wire as it issupplied from various positions on itssupply reel.

Similar means, comprising the rollers I20 and I2I, are provided forguiding the wire I06 from its supply reel 99 to the forming station.

Referring more particularly to Figs, '7 and 8, it will be seen that theelongated driving sleeve 36 is provided on its end with a counterboredportion I25 into which the forming die structures are adapted to befitted. The forming die structure, in the particular embodimentillustrated, comprises aseries of four disc or collar members I26, I21,I28 anud I29 held together as a structural unit by a series of studsI30, and adapted to be applied as a unit, after assembly together, tothe counterbored portion I25 of the driving sleeve. screw threaded intothe collar member I29, and are provided with enlarged head portions I3Iat their opposite ends, whereby to hold the collar members together as astructural unit. The die structure is held within the sleeve counterboreby means of a series of clamping set screws I32. The drive sleeve 36 isprovided with a diametrically extending bore or slot I33, Figs. 5 and 7,by

means of which the die structure may be ejected from thesleeve, uponinsertion of a suitable tool and upon loosening of the set screws I32,

The collar I26 carries a press fitted annular guide member or bushingI36 having a close sliding fit with the core wire for guiding the corewire I5 to the forming station, wh'ereas the collar I2] is provided witha pair of generally radially extending passages I31 and I38 for guidingthe wires I05 and I06 to the forming or winding station. Passages I39and I40 are also provided in the counterbored portion I25 of the drivingsleeve, for accommodating the Wires I 05 and I06. The collar I28 carriesa press fitted guide bushing I4I for loosely embracing and guiding thecompleted cable structure, and the collar I29 is provided with a centraltapered die portion I42 through which the completed cable 63 is adaptedto be forcibly drawn or projected whereby to be accurately gauged to apredetermined size.

In the operation of the structure, it will be seen that as the drivinsleeve 36 is rotated the supply reels 98 and 90 are bodily movedtherewith, and also rotated on the bolts 92 and 93 whereby to deliverthe wires I06 and I06, under predetermined tension, to the formingstation. At the forming station the wires I05 and I06 are wrappedtightly around the central core wire I5, the latter being non-rotatable,but longitudinal- 1y transmitted to the formin station from the supplyreel I4 through the sleeves I8 and 36. The completed cable, comprisingthe core wire I5 and the wrapped coil wires I05 and I06 are drawnthrough the sizing die I42, whereby to be accurately gauged to size. l

As will be understood, the studs I are By adjusting the change speedgear box 54' the drive wheel or roller 62 may be caused to withdraw thecompleted cable structure from the winding or forming head at anydesired rate, whereby to control the lead or pitch of the coil wires.For example, as illustrated in Figs. '7, 15' and 18, the cable structureis withdrawn from the forming head at a rate so that the coil wires I05and I06 will be in open pitch relationship. This open pitch arrangementreduces weight and cost in the completed structure, while at the sametime permittin the coil wires to reinforce the central core wire is atclosely spaced points so as to enable the core wire to directly absorbcompression as well as tension in the operation of the completed cablestructure. The features and ad.- vantages of av composite inner cablestructure of this type are discussed more fully in said copendingapplication, Serial No. 538,170.

It will be seen that the composite cable structure comprising the corewire I5 and the coil wires I05 and I06 may be continuously produced inan desired length, and accumulated upon the take-up reel 64. Thecomposite structure, in its final form, is produced in a singlecontinuous operation. The tension of the two wires, I05 and I96 isbalanced at the forming station. In this way there is no tendency topull the core wire I5 out of position, and the winding is eifected witha minimum distortion or stress of the wires, and a symmetrical anduniform structure is provided. It will further be noted that the bodilymovable Wire supply reels and 99 are disposed parallel ,to the axis ofrotation of the sleeve 36 so that centrifugal force of rotation does nottend to loosen or disturb the coils of wire on the supply reels. Bysubstitution of one or more of the die collars I26, I27, I28 and I29,cable structures of different sizes may be produced.

By varying the speed of the drive roller 62, the pitch of theconvolutions of the wires I05 and I 06, as they arewound upon the corewire I5, may be varied whereby to vary the stifiness of the completedcable structure 63. If the change speed gearing 54 is disconnected so asto permit the drive wheel 62 to turn freely, the coiling of the wiresI05 and I06 upon the central core wire will determine the rate oflongitudinal movement of the core wire and of the finished cablestructure, the finished cable in this instance being pushed rather thanpulled from the winding head. In this instance the convolutions of thecoil wires I 05 and I06 will be substantially in abutting relationship,as shown in Fig. 16.

In Figs. 15 and 16 the composite inner cable structures, formed by theapparatus, are illustrated within an outer exible sheath I45, which maycomprise a helical wire coil, whereby to providea flexible transmissioncable structure. As will be understood, the composite inner struc turecomprising the core wire I5 and the coil wires I05 and I06 is shiftableas a unit within the sheath or housing I45. The core wire I5 may, forexample, comprise a stranded cable, as shown, whereas the wires I05 andI06 are preferably of piano wire type. I

In Fig. 9 a modified arrangement is illustrated forproducing a cablestructure as shown in Fig 17, wherein the convolutions of the wires I05and I06 will be in alternate contacting and spaced relation, as may incertain instances bedesirable.

As shown in Fig. 9, the collar or disc member, I21

is in this instance replaced bycollarmember I2'Ia wherein the radialpassages I 3laand I 3811 are axially offset so as to provide the,desired a-eeeoo i In Figs. 1'0 and 1 1 an embodiment is muswaitedfofb'ioduei'ng a' cable as in Fig. I9, but wheiein' replacement ors'ubstitu'tidn bf the die cdlllr, such-Bethe tuner I 2%, is notrequired. In this instalfide the 6611a? member 1 21b, correspending in'fuficfibn :Bifldiifirpbs tbthe 0011211 member 421a previeus1y described,isreview with 'aummetrieany extending' bere 149. Plug members T56 9356.I 51 'Qfre' received Within'the bore W9, and adjustab'ly held therein bymeans of st s'cre'ws 152. The plug rneinb'ersaife p'rcivi'd'e'dmthrauial passages E3112 and 1381),- corres'pbnd ing' to' 'the' ra'diaIpassages previously described, but by rotaJtably-adjustingthe 'plug'r'rie'inb'ers, the axial "speicing-ofthe' radial-passages may be Varied.As will be seen by reference t'o 'Flg. 1'1, the-axial spacing ma bevaried over "23' relatively widewalngewithcut appreciably ehangin'gth'lat elalbffset'o'f the-fpas's'arges from the cen t'er lineeftherotatable driving sleev'fe" 36.

' varicius' numbers bf 'co'il wires, corresponding to the wires" 'mfiand 1%, ma be simultaneously wr'ap ee upon e core wire l'5, with'outdisturbing the -belaneeaor symmetricalcperation of the structure.

III-Fig. :I2' 9l forInin'g die member 12% is illusitreited, men as'wouldbe used-for wrapping three c'oihwi'res I; I'M- and [05c around thecentral core Wire 1' 5; in'sym'lnetrieal and balanced relat'ionslr-iip;

In Figs; 13' and -14 a modified fo'rm'nf winding] hea d ls illustrated;in-cbrporating -Ifi1eans' for radizny adjusting the sup ly reels for thewires I05 and H16, in the event o'f anu'ne'qual wiresdpp13 on the two're'els, s'das'f'to balance the centrifngal forces in 'theopei'atidn ofthe structure. In th ls instan th'Sl'lfiplyTlS 9821, and QML arecarried-by a-p'air'of studs I60 and Hi l secured tb-"an'd extending froma pair or clamp block-s I62 "a'n'd -l held in clemping engagement withthe drive s1'eeve 36,' by me'ans of bolts IB'E. Co'mpression springs I65urge the reels outwardly respecti velybn the studs lfiflan d "161 adistance permitted by adjustment nuts 56 By adjusting fihe ni1ts 1'56:the reels m y be individually shifted toward or away-from the 'axis' ofrotation of the sleeve 36"wh'ei"eby to compensate "for uneven weightsfof the wire on the reels. The compression springs I65 also provide africtional resistanceto"idtatidn dfthe reels upon their pivot stud'si Aswill 'seen' particularly by reference td' Figg 14,'thetwo supply fe'ls98a and swam in tra'nsvei'se a'llignm'e'nt, rather than b'eingffsetslightly, as in the structural embodiment pr'e'Viously des'cribed.

In Fig. 19% modified farm cf en-v'ihgm ns fdr withdrawing the completedcable" structure from the winding head is illustrated. In this ihstance,insteaddf u'si-n'g a singledrivin :r611ert2ga series of'drivin'g'roller's 62h, 15211 are 620 are prqvidefd, over which thecable 63 is-pas"s'e'd' intheme'nner illustrated; The r'oller- 62a may hedrivenfrom it's "drlve' shefit 59 -as- 'in' the structure -p're'vibuslydescribed, 'and therOllersHUand Bee-may be driven th*erewith by "meaznsof a flexible chain l 'ifl 'eng'ageable' with sprocket wheels TI I12ahd' [T31 fixed. to the drivin'g rellei s. In the arrange ment 10f" Fi i19, the cable 6'3 hasbnly 'a partia'l ne er contact with each drivinoner Any suitable numbermf drivmg :ro11ers -ma -be==em- @33Ai'1apparatus ;fdr'"' 'f di-niin;"the cbmiaositeintier" strutur'ebf "3.mechanicdrtrtms ssioncable compris ingwsupmy source for *cbre Wire','fatakeoff deyi'c'eymeansi fdi" f'guiiling' the -e-ore=wire from the supl yseu 1 n e tekeeri devi e el ri'gaipredtermmeaeath'br traVel,- arotatable windmg hee'uya sunn some fdr a plur elity (5f coil iwireseer'r'iea wifih sa'id heed, means" also carried with the heed "forguiding the coilwires fron' 'sa'id Ias't mmedsubply sour'c tc theforming statmnwrid 'means at tn-e refining station for ceiling the ecilwires eidund the core Wire 1112? terini'ne muinmepitemremtionship, saidlast -nqm'ed' ine-ens c'ompfi' sin forming member carriedwith thewindingheadfsaidformmg member haying anaxial-pelssatgfe throughWhi'ch'the core wire'is proplled aind e'plural ty ef rafdialpassegesextending radially outwardly from said" axial passage throughwhich thecoil wires are "ad'aptedto be moved, andmeansffer adjusting said formingmember to' vary 'the' axielpdsiti-oning 'ofthe radial passages.

4. AITeJpDaJratuS 'for forming" the composite 1nner' structure of i amechanicaltrensmissien cable cdmprising a "supply source fer coreWire,-=atalke'-' o'if device, means' for guiding the dbrewireff fom the-supply source thrqiig h a; forining station *te the'take-o'fideviceelong a predetermined p'fith of travel, a. rotatable winding"l'ia'ldi a supply source for a plurality of coil wires carried with saidhead, means also carried with the head for guiding the coil wires fromsaid last named supply source to the forming station, and means at theforming station for coiling the coil wires around the core wire inpredetermined multiple pitch relationship, said last named meanscomprising a forming member carried with the winding head, said formingmember having an axial passage through which the core wire is propelled,and a plurality of coplanar radial passages extending radially outwardlyfrom said axial passage and merging tangentially therewith through whichthe coil wires are adapted to be moved for varying the axial positioningof the radial passages of said forming member.

5,. An apparatus for forming the composite inner structure of amechanical transmission cable comprising a supply source for core wire,a take-01f device, means including an annular guide member having aclose sliding fit with the core wire for guiding the core wire from thesupply source through a forming station to the takeofi device along apredetermined path of travel, means for applying a predeterminedfriction to the core wire in its movement to the forming station, asupply source for coil wire, means including a rotatable head having aplurality of substantially radial coplanar passages for guiding the coilwire from said last named supply source to the forming station, andmeans at the forming station for coiling the coil wire around the corewire in predetermined pitch relationship.

6. An apparatus for forming the composite inner structure of amechanical transmission cable comprising a. supply source for core wire,a takeofi device, means including an annular guide member having a closesliding fit with the core wire for guiding the core wire from the supply10 source through a forming station to the take-off device along apredetermined path of travel, means for applying a predeterminedfriction to the core wire in its movement to the forming station, asupply source for a plurality of coil wires, means including a rotatablehead having a plurality of substantially radial coplanar passages forguiding the coil wires from said last named supply source to the formingstation, means for applying a predetermined friction to the coil wiresin their movement to the forming station, and means at the formingstation for coiling the cOil wires around the core wire in predeterminedmovable pitch relationship.

CHARLES A. ARENS.

REFERENCES CITED The following references are of record in the file ofthis patent:

UNITED STATES PATENTS Number Name Date 61,261 Rodgers Jan, 15, 1867187,943 Van Loon Feb. 27, 1877 334,709 Kruesi et a1 Jan. 19, 1886477,784 Sisum June 28, 1892 1,375,655 Heany Apr. 19, 1921 1,512,116Lightfoot Oct. 21, 1924 1,843,149 Eaton Feb, 2, 1932 1,984,405 Fant-oneet al Dec. 18, 1934 1,992,707 Lloyd 1 Feb. 26, 1935 2,095,551Johannessen et a1. Oct. 12, 1937 2,114,400 Parvin Apr. 19, 19382,114,496 Keating Apr. 19, 1938 FOREIGN PATENTS Number Country Date16,582 Switzerland June 8, 1898 155,797 Germany Nov. 4, 1904

